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EP0066571A1 - Synthetic mineral polymer compound of the silicoaluminates family and preparation process; molded articles containing such polymer compound and production process thereof. - Google Patents

Synthetic mineral polymer compound of the silicoaluminates family and preparation process; molded articles containing such polymer compound and production process thereof.

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Publication number
EP0066571A1
EP0066571A1 EP81902468A EP81902468A EP0066571A1 EP 0066571 A1 EP0066571 A1 EP 0066571A1 EP 81902468 A EP81902468 A EP 81902468A EP 81902468 A EP81902468 A EP 81902468A EP 0066571 A1 EP0066571 A1 EP 0066571A1
Authority
EP
European Patent Office
Prior art keywords
potassium
polymeric compound
mineral
phase
sio
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP81902468A
Other languages
German (de)
French (fr)
Other versions
EP0066571B1 (en
Inventor
Joseph Davidovits
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JOSEPH DAVIDOVITS TE ST.-QUENTIN, FRANKRIJK.
Original Assignee
Coordination Et Developpement De L'innovation Cordi SA Ste
CORDI COORD DEV INNOVATION
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Filing date
Publication date
Application filed by Coordination Et Developpement De L'innovation Cordi SA Ste, CORDI COORD DEV INNOVATION filed Critical Coordination Et Developpement De L'innovation Cordi SA Ste
Priority to AT81902468T priority Critical patent/ATE14107T1/en
Publication of EP0066571A1 publication Critical patent/EP0066571A1/en
Application granted granted Critical
Publication of EP0066571B1 publication Critical patent/EP0066571B1/en
Expired legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • C04B35/6316—Binders based on silicon compounds
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/20—Silicates
    • C01B33/26—Aluminium-containing silicates, i.e. silico-aluminates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B12/00—Cements not provided for in groups C04B7/00 - C04B11/00
    • C04B12/005—Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding

Definitions

  • Synthetic mineral polymeric compound from the family of silicoalu minates and process for its preparation; molded articles containing this polymeric compound and process for obtaining them.
  • the subject of the invention is the use of a mineral polycondensation reaction of reaction mixtures based on alkali silico-aluminates, for manufacturing, at low temperature, in principle below 120 ° C., molded mineral objects containing a mineral polymer. from the family of silico-aluminates and various mineral charges.
  • the mineral polycondensation reaction is close to that which is at the origin of the synthesis of very particular mineral products: synthetic zeolites or molecular sieves.
  • these particular structures are used for their ion exchange properties. They have a certain catalytic action on many organic polymerizations.
  • a large number of patents for the synthesis of these zeolites or molecular sieves describe the manufacturing processes of these particular minerals.
  • M being a valence cation n.
  • Many crystalline products have been obtained by various processes using this hydrothermal synthesis. The objective of all these processes is to obtain very porous products, generally in powder form, this crystalline powder possibly being then agglomerated by a binder. These products generally have poor mechanical characteristics.
  • An object of this invention is to describe the use of this hydrothermal synthesis, more precisely of this mineral polycondensation, in order to obtain mineral products with very superior technical and mechanical characteristics, allowing the manufacture of relatively hard mineral objects (5 to 7 in the Mohs scale), thermally stable, with a very fine surface definition, which can be used as an object, art object, building material, industrial mold, tool, or other technological applications such as ceramic mineral binder or coating.
  • relatively hard mineral objects 5 to 7 in the Mohs scale
  • thermally stable with a very fine surface definition, which can be used as an object, art object, building material, industrial mold, tool, or other technological applications such as ceramic mineral binder or coating.
  • the polymer (K) -PS described in this invention has a dif diagram X-ray fraction as shown in Table A.
  • the diagram is very similar to that of an extremely rare natural mineral, Kalioplilite KAlSiO 4 , responding well to the general formula of Polysialates.
  • This mineral is not a zeolite, but an anhydrous feldspar, that is to say that in the formula
  • the polymer product obtained does not correspond to the (Na, K) PSS obtained according to French patent application No. 79.22041, in particular the X-ray diagram, and thermogravimetry.
  • the product obtained is practically amorphous to X-rays, while the (Na, K) -PSS have an X-ray diagram close to that of the minerals Analcime, Gismondine, Gmelinite, Phillipsite.
  • Thermogravimetry indicates a weight loss of 5% in water up to 325 ° C then the weight remains constant, while the (Na, K) -PSS have a weight loss of between 21% and 29% between 100 ° C and 500 ° C.
  • the zeolitic character of the product is absent, while the macroscopic properties show a certain brittleness, although the product is hard: hardness 5 in the Mohs scale.
  • a synthetic Kaliophilite KAlSiO 4 , o, 1H 2 O was prepared by
  • a reaction mixture is used.
  • aqueous potassium potassium aluminate such that the composition of the reaction mixture expressed by the ratio of the oxides, corresponds to the values indicated in Table C.
  • the experimental value H 2 O is equal to the water present as solvent in the mixture, added water of chemical constitution of the compounds.
  • K-Polysialate, (K) -PS The ordinary method of preparing K-Polysialate, (K) -PS is to mix an aluminum silicate oxide in an aqueous solution of potassium polysilicate, with KOH potash.
  • This aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n is prepared from a polyhydroxy-aluminosilicate (Si 2 O 5 , Al 2 (OH) 4 ) n in which the aluminum cation is in the octahedral position and is hexacoordinated.
  • the polyhydroxy-aluminosilicate is transformed into an extremely reactive aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n in which the aluminum cation is tetracoordinated.
  • the polyhydroxy-aluminosilicates which can serve as raw material are the minerals corresponding to the class of clay minerals at 7 Angstroms, and having at least one aluminum cation in the octahedral layer subjacent to the tetrahedral layer of the silicon cation, such as for example natural minerals: alushite, carnat, china clay, lithomarge, specialtyokaolin, parakaolinite, pholénite, endellite glossecollite, halloysite, milanite, berthiérine, fraigonite, grovenite amesite, chamoisite.
  • the inorganic polymeric compound of the family of silico-aluminates obtained by polycondensation of a reaction mixture according to Table C, has a chemical composition expressed in terms of oxide of
  • the inorganic polymeric compound is in fact a solid solution comprising 35 to 90 parts by weight of a potassium polysilicate of formula (y-1) K 2 O: (x-2) SiO 2 : (w-1) H 2 O and from 10 to 65 parts by weight mineral polymer (K) PS of formula (K) n (-Si-O-Al-O-) n , nH 2 O of which
  • the reaction mixture corresponding to Table C, is not a gel; it is fluid and behaves like a mineral resin having interesting rheological properties when it is left to mature for approximately at least 1 hour at room temperature, for example 25 ° C.
  • this mineral resin is used either as it is, or with mineral and / or organic fillers, or as a binder or cement for mineral and / or organic products.
  • the resulting mass is then introduced into a mold, either by simple casting if the mixture is sufficiently fluid; either by compaction, or by pressure or vibration or other mechanical or physical means, then the assembly is brought to a temperature at most equal to 120 ° C, preferably between 60 ° C and 95 ° C.
  • the mineral object is removed from the mold or the impression and then dried at a temperature below 100 ° C.
  • the curing or polycondensation times are obviously a function of the temperature and the heating technique. At room temperature of 25 ° C, the curing time is 15 hours; at 50 ° C for 4 hours; at 85 ° C for 1 hour 30 minutes; at 90 ° C of Oh3Omin.
  • Other heating modes can also be used, such as high frequency, microwaves, Joule effect, embedded electrical resistance.
  • the reaction mixtures being polyelectrolytes, under these conditions the polycondensation times will be faster.
  • the order of introduction of the different reagents into the reaction mixture is important, especially if one wants to give the mineral resin a very long pot life, for example 2 to 4 hours in a workshop.
  • the industrial applications of the invention are thereby greatly facilitated. It is therefore necessary to avoid direct contact of the concentrated potassium hydroxide KOH with the aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n .
  • the aluminosilicate oxide or KOH To obtain the object of the invention, it is necessary to mask either the aluminosilicate oxide or KOH.
  • the masking of KOH takes place by the preparation of a strongly alkaline solution of potassium polysilicate. Then added to this solution the aluminosilicate oxide which is thus dissolved therein.
  • Another method of the invention consists, on the contrary, in masking the aluminosilicate oxide with an alkaline polysilicate solution, then in mixing this mixture with the concentrated KOH solution.
  • the latter method has the advantage of being able to achieve the object of the invention from two mixtures stable over time, allowing storage and easy handling.
  • the mineral resin obtained by allowing the reaction mixture to mature for approximately at least 1 hour at room temperature (25oC), or the mineral resin mixture (binder), are placed in a preferably closed mold.
  • the polycondensation reaction is carried out under hydrothermal conditions, and it is necessary to conserve all the water present in the reaction medium.
  • any surface evaporation will therefore be avoided either by using a closed mold or by covering it with any means of protection preventing the evaporation of water, such as a plastic film or a thin layer of a hydrophobic substance.
  • the solid thus obtained is separated from its mold, and dried.
  • the mold object thus obtained has very interesting physical and mechanical properties for the technological applications of the invention.
  • the ultra fine definition of the surface of the object obtained allows the extremely precise faithful reproduction of all the details, even the finest, of the impression and the mold. This reproduction precision is comparable in quality to that obtained with organic resins commonly used in reproduction and molding, such as epoxy resins. xy and polyurethanes, but in the case of the invention, the surface hardness of the object is equal to 5 to 7 in the Mohs scale, against at most 2 to 3 for organic resins.
  • Al 2 O 3 comes from the aluminosilicate oxide obtained by dehydr ⁇ xylation of a natural polyhydroxy-aluminosilicate
  • the fluid mixture is left mature for at least 1 hour at room temperature (25 ° C), then is poured into a mold.
  • the upper layer of the mass is covered with a polyethylene film and the whole is placed in an oven at 85oC for 1 hour 30 minutes. ; demoulded and after drying at 85 ° C, the density of the product is 1.7 grams per milliliter; the hardness is 4.5 on the Mohs scale; it is white, very little porous; physico-chemical analysis gives a molar composition of 1.5K 2 O: Al 2 O 3 : 4.1 SiO 2 : 3H 2 O corresponding to a polymeric compound containing in solid solution a phase of a potassium polysilicate of crude formula
  • the solid obtained has very clear cracks. These cracks disappear when, at the reaction mixture, after, during maturation, or even before, at least one mineral filler is added.
  • the molded articles thus obtained then have excellent physical and mechanical characteristics, such as for example a flexural strength of approximately 180 kg / cm 2 , a hardness which can reach 7 in the Mohs scale, a coefficient of linear expansion as a function of the temperature close to 2 to 5 .10 -6 m / m / ° C.
  • Example 2
  • Example 1 According to the technique described in Example 1), 960 grams of a reaction mixture containing H 2 O: 22.88 moles are prepared, the other constituents being unchanged.
  • the molar ratio of the reaction oxides is that of Table D, except for H 2 O / A 1 2 O 3 equal to 21.
  • the very fluid mixture is left mature for approximately 1 hour at room temperature, then 640 grams of synthetic cordierite, also containing Mullite, with a particle size of less than 120 microns, are added thereto.
  • the viscous mixture obtained is poured into a mold and hardened at 85 ° C for 1 h 30 min. as in Example 1). After drying at 85 ° C, the density of the product is 2.3 grams per milliliter, the hardness is equal to 5 Mohs; its dimensions indicate that the polycondensation has been carried out practically without shrinkage.
  • the X - ray examination is done using a different technique, recording the teta / 2 tetas curve, emission of the Cobalt line at 1.79 Angstroms.
  • Example 1 According to the technique described in Example 1), 792 grams of a reaction mixture containing H 2 O: 13.5 moles are prepared, the other constituents being unchanged.
  • the molar ratio of the reaction oxides is that of Table D, except for H 2 O / A1 2 O 3 equal to 12.5.
  • the fluid mixture is left to mature for approximately 1 hour at room temperature, then 540 grams of synthetic cordierite, also containing Mullite, with a particle size of less than 120 are added. microns. Then we proceed as in example 2).
  • the H 2 O / A1 2 O 3 ratio can vary between 10 and 25. However, it is preferable to approach values between 14 and 20. Larger values increase the porosity of the product obtained, while lower values seem to disturb the potassium silicate phase of the solid solution of the polymeric compound, accompanied by migration and free alkalinity. Also, in practice, we prefer to use reaction mixtures whose molar ratios of reactive oxides correspond to Table E;
  • Example 2 860 grams of the reaction mixture of Example 1) are prepared and 220 grams of Muscovite with a particle size of less than 120 microns and 90 grams of Calcium Fluoride F 2 Ca in fine powder are added thereto.
  • the viscous resin thus obtained is used to agglomerate 1 kg 150 grams of Zircon sand. This mixture is poured by vibration into a mold which is then placed at 85 ° C for 1 h 30 min. After drying, the product obtained has a density of 3.0 grams per milliliter. Its appearance is brilliant, its hardness is 6 in the Mohs scale.
  • the analysis of the X-ray diagram is very delicate, because in addition to the intense lines of Zircon and Calcium Fluoride, those very numerous of Muscovite cover practically all the lines characteristic of (K) -PS.
  • a reaction mixture is prepared according to Example 1). After maturation, the resin thus formed is applied with a brush, in a very thin layer on an imprint constituting the negative of a sculpture. At the same time, 5 kilograms of flint with a particle size between 0.5 and 5 mm are introduced into a mixer, and 0.5 kilograms, or 10% by weight of the flint, of this same mineral resin, are added thereto. To me the cloth is vibrated in the already coated impression and covered with a polyethylene film and allowed to harden at room temperature (25 °). The next day we unmold a sculpture with extremely thin, hard and shiny skin.
  • the potassium silicoaluminate reaction mixtures described in this invention make it possible to manufacture molded articles resulting from the agglomeration of 5 to 95 parts by weight of mineral and / or organic products and fillers, with 5 to 95 parts by weight of a binder consisting of a mineral polymeric compound whose composition expressed in terms of oxide is yK 2 O: Al 2 O 3 : xSiO 2 : wH 2 O in the hydrated form of which "w” is at most equal to 4, "x” is a value between approximately 3, 3 and 4.5, "y” is a value between approximately 0.9 and 1.6.
  • the inorganic polymeric compound is a solid solution comprising 35 to 90 parts by weight of a potassium polysilicate of formula
  • the molded objects have very high resistance to thermal shock.
  • the flame of a blowtorch can be applied directly to objects intended to undergo high temperatures, between 300oC and 1200 ° C, it is preferable to subject it to a heat treatment at a temperature at least equal to 325 ° C, in order to remove the constitution water.
  • the inorganic polymeric compound is dehydrated and dehydroxylated and is transformed into a product of equivalent or higher quality than that of ceramic materials, and has excellent thermal stability. Its composition expressed in the form of oxides is then: yK 2 O: Al 2 O 3 : xSiO 2 in which "x" is a value between 3.3 and 4.5 approximately,
  • y is a value between 0.9 and 1.6, approximately. It consists of a solid solution comprising a potassium polysilicate phase of composition
  • the potassium silicoaluminate reaction mixtures described in this invention constitute a mineral resin which can be used with at least one mineral and / or organic filler, or as a binder or cement. Polycondensation or hardening takes place either at room temperature or up to a temperature below 120oC. All fillers, as well as compatible auxiliary products can be added, we will cite without limitation of any kind: dyes and pigments, debubbling agents, reinforcing fibers, water-repellent agents.
  • the molded objects produced using the invention have multiple uses depending on the physical, mechanical or chemical characteristic involved: in industry, construction, decoration, in the form of an object, a mold, tool, block, panel, coating. They can undergo multiple subsequent physico-chemical, physical or mechanical treatments, as well as priming or finishing operations, plugging the porosity. If necessary, they will undergo a heat treatment at a temperature at least equal to approximately 325 ° C., transforming them into products having ceramic qualities, in particular excellent thermal and dimensional stability.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Silicates, Zeolites, And Molecular Sieves (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

Compose polymerique mineral de la famille des silicoaluminates, constitue d'une solution solide comprenant une phase de polysilicate de potassium de composition (y-1) K2O:(x-2) SiO2:(w-1) H20 dans laquelle "w" est une valeur au plus egale a 4, "x" est une valeur comprise entre 3,3 et 4,5, "y" est une valeur comprise entre 0,9 et 1,6, et phase de polymere polysialate de potassium de formule (FORMULE) le dit polymere polysialate de potassium ayant un diagramme aux rayons X voisin de celui d'un mineral naturel connu sous le nom de Kaliophilite KAISiO4. Procede de fabrication de ce polymere et du compose polymerique mineral, qui consiste a preparer un melange reactionnel a base de silicate de potassium, de potasse KOH et d'oxyde aluminosilicate (Si2O5, Al2O3)n, tel que les rapports molaires des produits reactionnels exprimes en termes d'oxydes soient compris ou egaux aux valeurs suivantes: K2O/SiO2 : 0,23 a 0,48 SiO2/Al2O3 : 3,3 a 4,5 H2O/Al2O3 : 10 a 25 K2O/Al2O3 : 0,9 a 1,60 puis a faire durcir ledit melange reactionnel a une temperature inferieure a 120 C. Utilisation dans la fabrication d'objets moules contenant au moins une charge minerale. Utilisation en tant que liant ou ciment. Fabrication d'objets resistant au choc thermique, d'objets d'art, de moules et outils.Mineral polymeric compound of the family of silicoaluminates, consisting of a solid solution comprising a potassium polysilicate phase of composition (y-1) K2O: (x-2) SiO2: (w-1) H20 in which "w" is a value at most equal to 4, "x" is a value between 3.3 and 4.5, "y" is a value between 0.9 and 1.6, and potassium polysialate polymer phase of formula ( FORMULATE) the so-called potassium polysialate polymer having an X-ray diagram close to that of a natural mineral known as Kaliophilite KAISiO4. Process for the production of this polymer and of the mineral polymeric compound, which consists in preparing a reaction mixture based on potassium silicate, potassium KOH and aluminosilicate oxide (Si2O5, Al2O3) n, such as the molar ratios of the expressed reaction products in terms of oxides are included or equal to the following values: K2O / SiO2: 0.23 to 0.48 SiO2 / Al2O3: 3.3 to 4.5 H2O / Al2O3: 10 to 25 K2O / Al2O3: 0.9 a 1.60 then hardening said reaction mixture at a temperature below 120 C. Use in the manufacture of molded objects containing at least one mineral filler. Use as a binder or cement. Manufacture of objects resistant to thermal shock, works of art, molds and tools.

Description

Composé polymérique minéral synthétique de la famille des silicoalu minates et procédé de préparation; objets moulés contenant ce composé polymérique et procédé d'obtention. Synthetic mineral polymeric compound from the family of silicoalu minates and process for its preparation; molded articles containing this polymeric compound and process for obtaining them.
L'invention a pour objet L'utilisation d'une réaction de polycondensa tion minérale de mélanges réactionnels à base de silico-aluminates alcalins, pour fabriquer , à basse température en principe inférieure à 120°C, des objets minéraux moulés contenant un polymère minéral de la famille des silico-aluminates et différentes charges minérales.The subject of the invention is the use of a mineral polycondensation reaction of reaction mixtures based on alkali silico-aluminates, for manufacturing, at low temperature, in principle below 120 ° C., molded mineral objects containing a mineral polymer. from the family of silico-aluminates and various mineral charges.
La réaction de polycondensation minérale est voisine de celle qui est à l'origine de la synthèse de produits minéraux bien particuliers: les zéolithes synthétiques ou tamis moléculaires. Ces produits ont une structure tri-dimensionnelle très caractéristique, qui est une succession d'assemblage de tétraèdres TO, (où T = Si, Al, Ga, P,) formant des canaux et cavités de dimensions régulières. Ces dimensions sont équivalentes à celles de la plupart des molécules organiques, ce qui explique l'utilisation de ces structures minérales pour filtrer les particules organiques de différentes dimensions. En plus, ces structures particulières sont utilisées pour leurs propriétés échangeuses d'ions. Elles ont une action catalytique certaine sur de nombreuses polymérisations organiques. Un grand nombre de brevets de synthèse de ces zéolithes ou tamis moléculaires décrivent les processus de fabrication de ces minéraux particuliers. Une documentation générale est constituée par l'ouvrage de D.W.Breck: "Zeolite Molecular Sieves" (Interscience Publishers John Wiley Se Sons, New York 1974.). 11 s'agit en général d'une synthèse hydrothermale à partir d'un gel de silico-alu- minate en présence de bases fortes en concentrations élevées. La réaction s'effectue en vase clos, à pression et température constantes, en présence d'un très large excès d'eau. En général, les conditions choisies sont la pression atmosphérique et des températures comprises entre 25°C et 125ºC , et les temps de réaction sont de plusieurs dizaines d'heures. La formule chimique brute de ces zéolithes synthétiques et tamis moléculaires est:The mineral polycondensation reaction is close to that which is at the origin of the synthesis of very particular mineral products: synthetic zeolites or molecular sieves. These products have a very characteristic three-dimensional structure, which is a succession of assembly of TO tetrahedra (where T = Si, Al, Ga, P,) forming channels and cavities of regular dimensions. These dimensions are equivalent to those of most organic molecules, which explains the use of these mineral structures to filter organic particles of different dimensions. In addition, these particular structures are used for their ion exchange properties. They have a certain catalytic action on many organic polymerizations. A large number of patents for the synthesis of these zeolites or molecular sieves describe the manufacturing processes of these particular minerals. A general documentation is constituted by the work of D.W.Breck: "Zeolite Molecular Sieves" (Interscience Publishers John Wiley Se Sons, New York 1974.). It is generally a hydrothermal synthesis from a silico-aluminum gel in the presence of strong bases in high concentrations. The reaction is carried out in a closed vessel, at constant pressure and temperature, in the presence of a very large excess of water. In general, the conditions chosen are atmospheric pressure and temperatures between 25 ° C and 125ºC, and the reaction times are several tens of hours. The raw chemical formula of these synthetic zeolites and molecular sieves is:
My/nAlySixO2(x+y)'wH2OM y / n Al y Si x O 2 (x + y) 'wH 2 O
M étant un cation de valence n. De nombreux produits cristallins ont été obtenus par divers procédés utilisant cette synthèse hydrothermale. L'objectif de tous ces procédés est l'obtention de produits très poreux, généralement en poudre, cette poudre cristalline pouvant être ensuite agglomérée par un liant. Ces produits ont en général des médiocres caractéristiques mécaniques.M being a valence cation n. Many crystalline products have been obtained by various processes using this hydrothermal synthesis. The objective of all these processes is to obtain very porous products, generally in powder form, this crystalline powder possibly being then agglomerated by a binder. These products generally have poor mechanical characteristics.
Un objet de cette invention est de décrire l'utilisation de cette synthèse hydrothermale, plus précisément de cette polycondensation minéraie, afin d'obtenir des produits minéraux dotés de caractéristiques techniques et mécaniques très supérieures, permettant la fabrication d'objets minéraux relativement durs ( 5 à 7 dans l'échelle de Mohs), stables thermiquement, d'une définition de surface très fine, pouvant être utilisés en tant qu'objet, objet d'art, matériau de construction, moule industriel, outil, ou autres applications technologiques comme liant minéral céramique ou revètement. A cet effet, il a été découvert que si on ne se plaçait pas dans des conditions réactionn elles qui favorisent la cristallisation, et la formation des cristaux, on aboutissait à des produits nouveaux.An object of this invention is to describe the use of this hydrothermal synthesis, more precisely of this mineral polycondensation, in order to obtain mineral products with very superior technical and mechanical characteristics, allowing the manufacture of relatively hard mineral objects (5 to 7 in the Mohs scale), thermally stable, with a very fine surface definition, which can be used as an object, art object, building material, industrial mold, tool, or other technological applications such as ceramic mineral binder or coating. To this end, it has been discovered that if one does not place oneself under reaction conditions which promote crystallization and the formation of crystals, one ends up with new products.
La description d'un polymère minéral nouveau, plus précisément d'un composé polymérique, et ses procédés de fabrication est l'objet principal de cette invention. L'utilisation de ce composé polymérique pour ses qualités permettant son utilisation en tant que liant minéral, est un autre objet de cette invention.The description of a new mineral polymer, more precisely of a polymeric compound, and its manufacturing methods is the main object of this invention. The use of this polymeric compound for its qualities allowing its use as an inorganic binder, is another object of this invention.
La terminologie utilisée pour ces polymères minéraux de structure tridimensionnelle, a été décrite dans les publications scientifiques suivantes: IUPAC International Symposium on Macromolecules, Stokholm 1976, Topic III, Applied Polymer Symposia; PACTEC IV, 1979, Society of Plastic Engineers, USA, Preprint page 151. Ces polymères minéraux appartiennent à la classe des polysialates de formule généraleThe terminology used for these mineral polymers of three-dimensional structure has been described in the following scientific publications: IUPAC International Symposium on Macromolecules, Stokholm 1976, Topic III, Applied Polymer Symposia; PACTEC IV, 1979, Society of Plastic Engineers, USA, Preprint page 151. These mineral polymers belong to the class of polysialates of general formula
Mn (-(SiO 2) z -A102-)n,wH2OM n (- (SiO 2 ) z -A10 2 -) n, wH 2 O
dans laquelle "z" peut être égal à 1,2 ou 3, "M" est un cation mono .valent, "n" est le degré de polymérisation. Dans le cadre de la présente invention, le polymère minéral correspond plus précisément à "z" = 1, soit la formule généralein which "z" can be equal to 1,2 or 3, "M" is a monovalent cation, "n" is the degree of polymerization. In the context of the present invention, the mineral polymer corresponds more precisely to "z" = 1, ie the general formula
Mn (-Si-O-Al-O-)n,wH2OM n (-Si-O-Al-O-) n , wH 2 O
O O En général, lorsqu'il s'agit de caractériser une espèce chimique bien particulière, outre l'analyse chimique, il est préférable d'utiliser aussi l'examen des diagrammes de diffraction aux Rayons X. Le polymère (K)-PS décrit dans cette invention possède un diagramme de dif fraction aux Rayons X comme indiqué dans le Tableau A. On a utilisé pour cela la méthode des poudres de Debye-Scherrer, émission K alpha du Cuivre.OO In general, when characterizing a very specific chemical species, in addition to chemical analysis, it is preferable to also use the examination of X-ray diffraction diagrams. The polymer (K) -PS described in this invention has a dif diagram X-ray fraction as shown in Table A. The Debye-Scherrer powder method, K alpha emission from Copper, was used for this.
Le diagramme est très voisin de celui d'un minéral naturel extrèmement rare, la Kalioplilite KAlSiO4, répondant bien à la formule géné raie des Polysialates. Ce minéral n'est pas une zéolithe, mais un feldspathoide anhydre, c'est à dire que dans la formuleThe diagram is very similar to that of an extremely rare natural mineral, Kalioplilite KAlSiO 4 , responding well to the general formula of Polysialates. This mineral is not a zeolite, but an anhydrous feldspar, that is to say that in the formula
Kn (Si-O-Al-O)n,wH2OK n (Si-O-Al-O) n , wH 2 O
O OO O
"w" est compris entre 0 et 1. Cette distinction est importante. En effet, les polymères minéraux contenant de l'eau de constitution zéolithique, doivent être déshydratés et déshydroxylés, par une sèche ménagée allant jusque 400°C environ avant de pouvoir supporter sans dommage le choc thermique à plus haute tampérature. Au contraire un minéral, du type de la Kaliophili te subira sans dommage le choc thermique, car sa structure ne sera pas modifiée. Ce test de la tenue au choc thermique, par exemple sous la flamme d'un chalumeau, est aussi un moyen rapide de constater la présence ou non d'une structure zéolithique ou feldspathoidique Mais le plus surprenant dans le cas du Polysialate (K)-PS objet de cette invention, et dont la composition en terme d'oxyde est"w" is between 0 and 1. This distinction is important. In fact, the mineral polymers containing water with a zeolitic constitution must be dehydrated and dehydroxylated, using a gentle dryer up to approximately 400 ° C. before they can withstand the thermal shock at higher temperatures without damage. On the contrary a mineral, of the type of Kaliophili will undergo you without damage the thermal shock, because its structure will not be modified. This test of resistance to thermal shock, for example under the flame of a blowtorch, is also a rapid means of noting the presence or not of a zeolitic or feldspathoid structure. But the most surprising in the case of Polysialate (K) PS object of this invention, and whose composition in terms of oxide is
K2O:Al2O3:2SiO2:H2OK 2 O: Al 2 O 3 : 2 SiO 2 : H 2 O
c'est que sa synthèse demande un rapport SiO2/Al2O3 supérieur aux quantités stoechiométriques, c'est à dire supérieur à 2, puisqu'il est compris entre 3,3 et 4, 5. Cette découverte surprenante fut faite au cours d'un développement ultérieur d'un procédé décrit par le brevet français nº79.22041 déposé par la demanderesse, et relatif à la synthèse de polymères minéraux (Na,K)Poly(sialate-siloxo) ouis that its synthesis requires a SiO 2 / Al 2 O 3 ratio greater than the stoichiometric quantities, ie greater than 2, since it is between 3.3 and 4.5. This surprising discovery was made at during a further development of a process described by French patent n ° 79.22041 filed by the applicant, and relating to the synthesis of mineral polymers (Na, K) Poly (sialate-siloxo) or
(Na,K)-PSS de formule générale (Na,K)n(-Si-O-Al-O-Si-O-)n,wH2O(Na, K) -PSS of general formula (Na, K) n (-Si-O-Al-O-Si-O-) n , wH 2 O
O O OO O O
Les rapports molaires des réactifs utilisés dans la synthèse du (Na,K)-PSS selon la demande de brevet français 79.22041 sont:The molar ratios of the reagents used in the synthesis of (Na, K) -PSS according to French patent application 79.22041 are:
(Na2O,K2O)/SiO2 0,20 à 0,28 SiO2/Al2O3 3,5 à 4, 5(Na 2 O, K 2 O) / SiO 2 0.20 to 0.28 SiO 2 / Al 2 O 3 3.5 to 4.5
H2O /(Na2O,K2O) 15 à 17,5 (Na2O,K2O)/Al2O3 0,8 à 1,20 H 2 O / (Na 2 O, K 2 O) 15 to 17.5 (Na 2 O, K 2 O) / Al 2 O 3 0.8 to 1.20
Si on utilise exclusivement comme réactifs un polysilicate de potassium, de la potasse KOH, et l ' oxyde alumino-silicate (Si2O5,Al2O2)n , le produit polymérique obtenu ne correspond pas aux ( Na , K)PSS obtenus selon la demande de brevet français n ° 79.22041 , en particulier le diagramme aux Rayons X, et la thermogravimétrie. Le produit obtenu est pratiquement amorphe aux Rayons X, alors que les (Na , K)-PSS ont un diagramme aux Rayons X voisin de celui des minéraux Analcime, Gismondine, Gmelinite, Phillipsite. La thermogravimétrie indique une perte de poids en eau de 5% jusqu ' à 325 °C puis le poids reste constant, alors que les (Na ,K )-PSS ont une perte de poids comprise entre 21% et 29% entre 100°C et 500°C. Le caractère zéolithique du produit est absent, tandis que les propriétés macroscopiques montrent une certaine fragilité, bien que le produit soit dur: dureté 5 dans l ' échelle de Mohs. Une Kaliophilite de synthèse KAlSiO4 ,o, 1H2O a été préparée parIf potassium polysilicate, potassium KOH and aluminum silicate oxide (Si 2 O 5 , Al 2 O 2 ) n are used exclusively as reactants, the polymer product obtained does not correspond to the (Na, K) PSS obtained according to French patent application No. 79.22041, in particular the X-ray diagram, and thermogravimetry. The product obtained is practically amorphous to X-rays, while the (Na, K) -PSS have an X-ray diagram close to that of the minerals Analcime, Gismondine, Gmelinite, Phillipsite. Thermogravimetry indicates a weight loss of 5% in water up to 325 ° C then the weight remains constant, while the (Na, K) -PSS have a weight loss of between 21% and 29% between 100 ° C and 500 ° C. The zeolitic character of the product is absent, while the macroscopic properties show a certain brittleness, although the product is hard: hardness 5 in the Mohs scale. A synthetic Kaliophilite KAlSiO 4 , o, 1H 2 O was prepared by
H. Besson, S.Caillère et S. Hénin ( Comptes Rendus Académie des Sciences de Paris ,, tome 272, série D, pages 2749-2752) , 1971) , à partir de gels silico-alumineux et de carbonate de potassium K2CO3; cette Kaliophilite de synthèse, anhydre , possède un diagramme aux Rayons X indiqué dans le tableau A. Ce diagramme est pratiquement identique à celui du ( K )-PS, sauf que dans le cas de la Kaliophilite, la large raie allant de 2- 79 à 3.23 Angstroms est ici accompagnée d ' une raie intense, en son milieu à 3.10 Angstroms. Parmi les zéolithes de synthèse pouvant se rapprocher du polymère (K)-PS, on peut citer la Zéolithe Z (ou Zéolithe KF ) , la Zéolithe G(ou Zéolithe K-G) , la Zéolithe W (ou Zéolithe K-M , K-H) et dont les diagrammes aux Rayons X sont reproduits également dans le Tableau A, d ' après l ' ouvrage de D . W. Breck cité ci-dessus. Le Tableau B reproduit les rapports molaires entre les différents oxy des réactifs utilisés dans les synthèses des produits cités dans le tableau A.H. Besson, S. Caillère and S. Hénin (Comptes Rendus Académie des Sciences de Paris ,, tome 272, série D, pages 2749-2752), 1971), from silico-aluminous gels and potassium carbonate K 2 CO 3 ; this anhydrous synthetic Kaliophilite has an X-ray diagram indicated in Table A. This diagram is practically identical to that of (K) -PS, except that in the case of Kaliophilite, the wide line ranging from 2-79 at 3.23 Angstroms is here accompanied by an intense stripe, in the middle at 3.10 Angstroms. Among the synthetic zeolites which can be approached from the polymer (K) -PS, mention may be made of Zeolite Z (or zeolite KF), Zeolite G (or zeolite KG), Zeolite W (or zeolite KM, KH) and whose X-ray diagrams are also reproduced in Table A, based on the work of D. W. Breck cited above. Table B reproduces the molar ratios between the various oxy of the reagents used in the syntheses of the products cited in Table A.
Pour préparer le K-Poly sialate ou ( K)-PS , on utilise un mélange réac tionnel acqueux de silico-aluminate de potassium, tel que la composition du mélange réactionnel exprimé par le rapport des oxydes , corresponde aux valeurs indiquées dans le Tableau C. La valeur expérimentale H2O est égale à l ' eau présente en tant que solvant dans le mélange, ajoutée de l ' eau de constitution chimique des composés.To prepare K-Poly sialate or (K) -PS, a reaction mixture is used. aqueous potassium potassium aluminate, such that the composition of the reaction mixture expressed by the ratio of the oxides, corresponds to the values indicated in Table C. The experimental value H 2 O is equal to the water present as solvent in the mixture, added water of chemical constitution of the compounds.
La méthode ordinaire de préparation du K-Polysialate , (K)-PS consiste à mélanger un oxyde alumino-silicate dans une solution acqueuse de polysilicate de potassium, avec de la potasse KOH. Cet oxyde aluminosilicate (Si2O5,Al2O2) n est préparé à partir d'un polyhydroxy-aluminosilicate (Si2O5,Al2(OH) 4)n dans lequel de cation aluminium se trouve en position octaèdrique et est hexacoordonné. Par déshydroxyiation à une température comprise entre 550°C et 800ºC, le polyhydroxy-aluminosilicate se transforme en un oxyde aluminosilicate extrèmement réactif (Si2O5,Al2O2)n dans lequel le cation aluminium est tétracoordonné. Les poiyhydroxy-aluminosilicates pouvant servir de matière première sont les minéraux répondant à la classe des minéraux argileux à 7 Angstroms, et possédant au moins un cation aluminium dans la couche octaèdrique sousjascente à la couche tétraèdrique du cation silicium, comme par exemple les minéraux naturels : alushite , carnat, china clay, lithomarge, néokaolin, parakaolinite, pholénite , endellite glossecollite , halloysite, milanite, berthiérine, fraigonite, grovénite amésite, chamoisite. The ordinary method of preparing K-Polysialate, (K) -PS is to mix an aluminum silicate oxide in an aqueous solution of potassium polysilicate, with KOH potash. This aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n is prepared from a polyhydroxy-aluminosilicate (Si 2 O 5 , Al 2 (OH) 4 ) n in which the aluminum cation is in the octahedral position and is hexacoordinated. By dehydroxyiation at a temperature between 550 ° C and 800ºC, the polyhydroxy-aluminosilicate is transformed into an extremely reactive aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n in which the aluminum cation is tetracoordinated. The polyhydroxy-aluminosilicates which can serve as raw material are the minerals corresponding to the class of clay minerals at 7 Angstroms, and having at least one aluminum cation in the octahedral layer subjacent to the tetrahedral layer of the silicon cation, such as for example natural minerals: alushite, carnat, china clay, lithomarge, néokaolin, parakaolinite, pholénite, endellite glossecollite, halloysite, milanite, berthiérine, fraigonite, grovenite amesite, chamoisite.
Le composé polymérique minéral de la famille des silico-aluminates , obtenu par polycondensation d ' un mélange réactionnel selon le Tabbleau C, a une composition chimique exprimée en terme d ' oxyde deThe inorganic polymeric compound of the family of silico-aluminates, obtained by polycondensation of a reaction mixture according to Table C, has a chemical composition expressed in terms of oxide of
yK2O:Al2O3:xSiO2:wH2OyK 2 O: Al 2 O 3 : xSiO 2 : wH 2 O
dans la forme hydratée de laquelle "w" est au plus égal à 4, "x" est une valeur comprise entre 3,3 et 4,5 environ, "y" est une valeur comprise entre 0, 9 et 1 , 6 environ. "" Le composé polymérique minéral est en fait une solution solide comprenant 35 à 90 parties en poids d ' un polysilicate de potassium de formule (y-1)K2O : (x-2)SiO2 : (w-1 )H2O et de 10 à 65 parties en poids du polymère minéral ( K) PS de formule ( K) n (-Si-O-Al-O-) n , nH2O dontin the hydrated form of which "w" is at most equal to 4, "x" is a value between approximately 3.3 and 4.5, "y" is a value between approximately 0.9 and 1.6. "" The inorganic polymeric compound is in fact a solid solution comprising 35 to 90 parts by weight of a potassium polysilicate of formula (y-1) K 2 O: (x-2) SiO 2 : (w-1) H 2 O and from 10 to 65 parts by weight mineral polymer (K) PS of formula (K) n (-Si-O-Al-O-) n , nH 2 O of which
O O le diagramme de diffraction aux Rayons X est voisin de celui du mirai naturel Kaliophilite, selon le Tableau A. La quantité en produits intervenant dans la réaction , à savoir le polysilicate de potassium, la potasse KOH, l 'oxyde aluminosilicate, correspond aux valeurs données par le Tableau C. On constate que ces conditions réactionnelles sont différentes de celles habituellement utilisées dans la synthèse des Zéolithes Z, G, W , comme le montre le Tableau B . En particulier, dans ces procédés l ' eau est en grand excès et les quantités en K2O sont très supérieures à celles employées dans l ' invention. Selon l ' invention , on utilisera de préférence un rapport SiO2/Al O3 proche de 4 à 4,2 et un rapport K2O/Al2O3 compris entre 1 ,3 et 1 ,52. Des rapports, plus grands se traduisent par une quantité trop importante de la phase silicate de potassium dans la solution solide du composé polymérique, c ' est à dire par une alcalinité libre et des migrations de silicate de potassium qui peuvent perturber les propriétés physiques et chimiques des matériaux ainsi réalisés. Des rapports plus petits , par exemple inférieurs à 3 , 7 et 1 , 1 respectivement, fournissent des matériaux qui sont entièrement fissurés et ne peuvent donc pas servir à la fabrication d 'objet .OO the X-ray diffraction diagram is close to that of the natural Kaliophilite mirai, according to Table A. The amount of products involved in the reaction, namely potassium polysilicate, KOH potash, aluminosilicate oxide, corresponds to the values given by Table C. It can be seen that these reaction conditions are different from those usually used in the synthesis of Zeolites Z, G, W, as shown in Table B. In particular, in these processes the water is in great excess and the amounts of K 2 O are much greater than those employed in the invention. According to the invention, a SiO 2 / Al O 3 ratio close to 4 to 4.2 and a K 2 O / Al 2 O 3 ratio of between 1.3 and 1.52 will preferably be used. Larger ratios result in too large a quantity of the potassium silicate phase in the solid solution of the polymeric compound, that is to say by free alkalinity and migrations of potassium silicate which can disturb the physical and chemical properties. materials thus produced. Smaller ratios, for example less than 3, 7 and 1, 1 respectively, provide materials which are fully cracked and therefore cannot be used in the manufacture of the object.
Le mélange réactionnel, correspondant au Tableau C, n ' est pas un gel; il est fluide et se comporte comme une résine minérale ayant des propriétés rhéologiques intéressantes lorsque on le laisse maturer pendant environ au moins 1 heure à une température ambiante, par exemple 25°C. Après cette maturation , cette résine minérale est utilisée soit telle quelle, soit avec des charges minérales et/ou organiques , soit en tant que liant ou ciment de produits minéraux et/ou organiques. La masse qui en résulte est alors introduite dans un moule , soit par simple coulée si le mélange est suffisamment fluide ; soit par tassement, soit par pression ou vibration ou autre moyen mécanique ou physique, puis l ' ensemble est porté à une température au plus égale à 120°C, de préférence entre 60°C et 95°C. AprèsThe reaction mixture, corresponding to Table C, is not a gel; it is fluid and behaves like a mineral resin having interesting rheological properties when it is left to mature for approximately at least 1 hour at room temperature, for example 25 ° C. After this maturation, this mineral resin is used either as it is, or with mineral and / or organic fillers, or as a binder or cement for mineral and / or organic products. The resulting mass is then introduced into a mold, either by simple casting if the mixture is sufficiently fluid; either by compaction, or by pressure or vibration or other mechanical or physical means, then the assembly is brought to a temperature at most equal to 120 ° C, preferably between 60 ° C and 95 ° C. After
polycondensation , l 'objet minéral est sorti du moule ou de l ' empreinte puis séché à une température inférieure à 100°C. Les temps de durcissement ou de polycondensation sont évidemment fonction de la température et de la technique de chauffage. A la température ambiante de 25°C, le temps de durcissement est de 15 heures ; à 50°C de 4 heures ; à 85°C de lh30min; à 90°C de Oh3Omin. On peut utiliser également d' autres modes de chauffage, comme la haute fréquence, les microondes, l' effet Joule, la résistance électrique noyée. Les mélanges réactionnels étant des polyélectrolytes , dans ces conditions les temps de polycondensation seront plus rapides.polycondensation, the mineral object is removed from the mold or the impression and then dried at a temperature below 100 ° C. The curing or polycondensation times are obviously a function of the temperature and the heating technique. At room temperature of 25 ° C, the curing time is 15 hours; at 50 ° C for 4 hours; at 85 ° C for 1 hour 30 minutes; at 90 ° C of Oh3Omin. Other heating modes can also be used, such as high frequency, microwaves, Joule effect, embedded electrical resistance. The reaction mixtures being polyelectrolytes, under these conditions the polycondensation times will be faster.
L 'ordre d ' introduction des différents réactifs dans le mélange réactionnel est important, surtout si l 'on veut donner à la résine minérale une durée de vie en pot (potlife) très longue, par exemple 2 à 4 heures dans un atelier. Les applications industrielles de l ' invention s ' en trouvent grandement facilitées. 11 est pour cela nécessaire d ' éviter le contact direct de la potasse concentrée KOH avec l ' oxyde aluminosilicate (Si2O5,Al2O2) n . Pour obtenir l ' objet de l ' invention , il est nécessaire de masquer soit l 'oxyde aluminosilicate, soit KOH. Le masquage de KOH a lieu par la préparation d 'une solution fortement alcaline du polysilicate de potassium. On ajoute ensuite dans cette solution l 'oxyde aluminosilicate qui s ' y trouve ainsi dissout. Une autre méthode de l ' invention consiste au contraire à masquer l 'oxyde aluminosilicate par une solution de polysilicate alcalin , puis à mélanger ce mélange avec la solution concentrée de KOH. Cette dernière méthode possède l' avantage de pouvoir réaliser l'objet de l' invention à partir de deux mélanges stables dans le temps, permettant le stockage et les facilités de manipulation. La résine minérale obtenue en laissant maturer le mélange réactionnel pendant environ au moins 1 heure à température ambiante (25ºC) , ou le mélange résine minérale (liant ) , sont placés dans un moule de préférence fermé. La réaction de polycondensation s ' effectue dans des conditions hydrothermales , et il est nécessaire de conserver toute l ' eau présente dans le milieu réactionnel . On évitera donc toute évaporation superficielle soit en utilisant un moule fermé , soit en le recouvrant avec tout moyen de protection évitant l ' évaporation de l 'eau, comme un film plastique ou une fine couche d ' une substance hydrophobe. Après avoir durci dans le moule, on sépare de son moule le solide ainsi obtenu , et on sèche. L 'objet moule ainsi obtenu est doté de propriétés physiques et mécaniques très intéressantes pour les applications technologiques de l ' invention. En particulier, la définition ultra fine de la surface de l 'objet obtenu permet la reproduction fidèle extrèmement précise de tous les détails , même les plus fins , de l ' empreinte et du moule. Cette précision de reproduction est comparable en qualité à celle obtenue avec des résines organiques utilisées couramment dans la reproduction et le moulage, comme les résines épo xy et polyuréthanes, mais dans le cas de l'invention, la dureté de surface de l'objet est égale à 5 à 7 dans l'échelle de Mohs, contre au maximum 2 à 3 pour les résine organiques.The order of introduction of the different reagents into the reaction mixture is important, especially if one wants to give the mineral resin a very long pot life, for example 2 to 4 hours in a workshop. The industrial applications of the invention are thereby greatly facilitated. It is therefore necessary to avoid direct contact of the concentrated potassium hydroxide KOH with the aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n . To obtain the object of the invention, it is necessary to mask either the aluminosilicate oxide or KOH. The masking of KOH takes place by the preparation of a strongly alkaline solution of potassium polysilicate. Then added to this solution the aluminosilicate oxide which is thus dissolved therein. Another method of the invention consists, on the contrary, in masking the aluminosilicate oxide with an alkaline polysilicate solution, then in mixing this mixture with the concentrated KOH solution. The latter method has the advantage of being able to achieve the object of the invention from two mixtures stable over time, allowing storage and easy handling. The mineral resin obtained by allowing the reaction mixture to mature for approximately at least 1 hour at room temperature (25ºC), or the mineral resin mixture (binder), are placed in a preferably closed mold. The polycondensation reaction is carried out under hydrothermal conditions, and it is necessary to conserve all the water present in the reaction medium. Any surface evaporation will therefore be avoided either by using a closed mold or by covering it with any means of protection preventing the evaporation of water, such as a plastic film or a thin layer of a hydrophobic substance. After having hardened in the mold, the solid thus obtained is separated from its mold, and dried. The mold object thus obtained has very interesting physical and mechanical properties for the technological applications of the invention. In particular, the ultra fine definition of the surface of the object obtained allows the extremely precise faithful reproduction of all the details, even the finest, of the impression and the mold. This reproduction precision is comparable in quality to that obtained with organic resins commonly used in reproduction and molding, such as epoxy resins. xy and polyurethanes, but in the case of the invention, the surface hardness of the object is equal to 5 to 7 in the Mohs scale, against at most 2 to 3 for organic resins.
Les exemples qui suivent illustrent les procédés de préparation de ce composé polymérique contenant en solution solide le (K)-PS, et permettent de décrire certaines de ses propriétés.The examples which follow illustrate the processes for preparing this polymeric compound containing the (K) -PS in solid solution, and make it possible to describe some of its properties.
Exemple 1 )Example 1)
On prépare 860 grammes d'un mélange contenant:860 grams of a mixture containing:
H2O: 17,33 moles ; K2O: 1,630 moles ; SiO2: 4,46 moles et Al2O3: 1,081 moles. Al2O3 provient de l'oxyde aluminosilicate obtenu par déshydrαxylation d'un polyhydroxy-aluminosilicate naturelH 2 O: 17.33 moles; K 2 O: 1.630 moles; SiO 2 : 4.46 moles and Al 2 O 3 : 1.081 moles. Al 2 O 3 comes from the aluminosilicate oxide obtained by dehydrαxylation of a natural polyhydroxy-aluminosilicate
(Si2O5, Al2 (OH)4)n et SiO2 provient également de cet oxyde aliminosilica te et d'une solution de silicate de potassium. K2O provient du silicate de potassium et de KOH anhydre. Le rapport molaire des oxydes réactionnels est donné par le Tableau D :(Si 2 O 5 , Al 2 (OH) 4 ) n and SiO 2 also comes from this aliminosilica oxide and from a potassium silicate solution. K 2 O comes from potassium silicate and anhydrous KOH. The molar ratio of the reaction oxides is given in Table D:
Le mélange fluide est laissé mature pendant au moins 1 heure à température ambiante (25°C), puis est coulé dans un moule. La couche supérieure de la masse est recouverte par un film de polyéthylène et l'ensemble est placé dans une étuve à 85ºC pendant lh30min. ; on démoule et après sèche à 85°C , la densité du produit est de 1,7 grammes par millilitre; la dureté est à 4,5 dans l'échelle de Mohs; il est blanc, très peu poreux; l'analyse physico-chimique donne une composition molaire de 1,5K2O:Al2O3:4,1SiO2:3H2O correspondant à un composé polymérique contenant en solution solide une phase d'un polysilicate de potassium de formule bruteThe fluid mixture is left mature for at least 1 hour at room temperature (25 ° C), then is poured into a mold. The upper layer of the mass is covered with a polyethylene film and the whole is placed in an oven at 85ºC for 1 hour 30 minutes. ; demoulded and after drying at 85 ° C, the density of the product is 1.7 grams per milliliter; the hardness is 4.5 on the Mohs scale; it is white, very little porous; physico-chemical analysis gives a molar composition of 1.5K 2 O: Al 2 O 3 : 4.1 SiO 2 : 3H 2 O corresponding to a polymeric compound containing in solid solution a phase of a potassium polysilicate of crude formula
0,5K2O:2,1SiO2: 2H2O et un (K)-PS (K)n(-Si-O-Al-O-)n,nH2O0.5K 2 O: 2.1 SiO 2 : 2H 2 O and a (K) -PS (K) n (-Si-O-Al-O-) n , nH 2 O
O O Le diagramme aux rayons X effectué par la méthode des poudres Debye-Scherrer, raie K alpha du Cuivre, chambre de 57,3mm de ruyon, donne les raies du ( K)-PSS reproduites dans le Tableau A.OO The X-ray diagram made by the Debye-Scherrer powder method, K alpha line of Copper, 57.3mm chamber of ruyon, gives the (K) -PSS lines shown in Table A.
Le solide obtenu présente cependant des fissures très nettes . Ces fisssurations disparaissent lorsque, au mélange réactionnel, après , ou pendant la maturation , ou même avant, on ajoute au moins une charge minérales. Les objets moulés ainsi obtenus ont alors des caractéristiques physiques et mécaniques excellentes , comme par exemple une résistance à la flexion d ' environ 180kg/cm2 , une dureté pouvant attein- 7 dans l' échelle de Mohs, un coefficient de dilatation linéaire en fonction de la température voisin de 2 à 5 .10-6 m/m/°C. Exemple 2 )However, the solid obtained has very clear cracks. These cracks disappear when, at the reaction mixture, after, during maturation, or even before, at least one mineral filler is added. The molded articles thus obtained then have excellent physical and mechanical characteristics, such as for example a flexural strength of approximately 180 kg / cm 2 , a hardness which can reach 7 in the Mohs scale, a coefficient of linear expansion as a function of the temperature close to 2 to 5 .10 -6 m / m / ° C. Example 2)
Selon la technique décrite dans l ' Exemple 1 ) , on prépare 960 grammes d'un mélange réactionnel contenant H2O: 22,88 moles, les autres constituants étant inchangés. Le rapport molaire des oxydes réactionnels est celui du Tableau D , sauf pour H2O/A 12O3 égal à 21.According to the technique described in Example 1), 960 grams of a reaction mixture containing H 2 O: 22.88 moles are prepared, the other constituents being unchanged. The molar ratio of the reaction oxides is that of Table D, except for H 2 O / A 1 2 O 3 equal to 21.
Le mélange très fluide est laissé mature pendant environ 1 heure à température ambiante, puis on y ajoute 640 grammes de Cordiérite synthétique contenant également de la Mullite, de granulométrie inférieure à 120 microns. Le mélange visqueux obtenu est coulé dans un moule et durci à 85°C pendant lh30min. comme dans l ' Exemple 1) . Après sèche à 85°C, la densité du produit est de 2,3 grammes par millilitre, la dureté est égale à 5 Mohs ; ses dimensions indiquent que la polycondensation s ' est effectuée pratiquement sans retrait. L ' examen aux Rayons X est fait à l ' aide d ' une technique différente, l ' enregistrement de la courbe téta/2 tétas, émission de la raie du Cobalt à 1 ,79 Angstroms. Outre les raies très intenses de la Cordiérite et celles assez fortes de la Mullite , on distingue des raies faiblement intenses à 4.49/4.28/3.53/2.59/2.28/2.16 Angstroms ainsi qu ' une zone entre 10.00 et 11.8 Angstroms. Ce diagramme est celui du ( K) PS indiqué dans le Tableau A , seule la zone entre 3.38 et 2.80 Angstroms étant recouverte par les intenses raies de la Cordiérite. Exemple 3 )The very fluid mixture is left mature for approximately 1 hour at room temperature, then 640 grams of synthetic cordierite, also containing Mullite, with a particle size of less than 120 microns, are added thereto. The viscous mixture obtained is poured into a mold and hardened at 85 ° C for 1 h 30 min. as in Example 1). After drying at 85 ° C, the density of the product is 2.3 grams per milliliter, the hardness is equal to 5 Mohs; its dimensions indicate that the polycondensation has been carried out practically without shrinkage. The X - ray examination is done using a different technique, recording the teta / 2 tetas curve, emission of the Cobalt line at 1.79 Angstroms. In addition to the very intense lines of Cordierite and those fairly strong of Mullite, there are weakly intense lines at 4.49 / 4.28 / 3.53 / 2.59 / 2.28 / 2.16 Angstroms as well as a zone between 10.00 and 11.8 Angstroms. This diagram is that of the (K) PS indicated in Table A, only the area between 3.38 and 2.80 Angstroms being covered by the intense lines of Cordierite. Example 3)
Selon la technique décrite dans l ' Exemple 1 ) , on prépare 792 grammes d ' un mélange réactionnel contenant H2O : 13 ,5 moles , les autres constituants étant inchangés.According to the technique described in Example 1), 792 grams of a reaction mixture containing H 2 O: 13.5 moles are prepared, the other constituents being unchanged.
Le rapport molaire des oxydes réactionnels est celui du tableau D , sauf pour H2O/A12O3 égal à 12,5.The molar ratio of the reaction oxides is that of Table D, except for H 2 O / A1 2 O 3 equal to 12.5.
Le mélange fluide est laissé maturer pendant environ 1 heure à température ambiante, puis on ajoute 540 grammes de Cordiérite synthétique contenant également de la Mullite, de granulométrie inférieure à 120 microns. Puis on procède comme dans l ' exemple 2) .The fluid mixture is left to mature for approximately 1 hour at room temperature, then 540 grams of synthetic cordierite, also containing Mullite, with a particle size of less than 120 are added. microns. Then we proceed as in example 2).
L ' examen aux Rayons X fait comme dans l ' exemple 2) , montre les mêmes raies du (K )-PS avec en plus des raies faiblement intenses à 3.24/2.95/2.88/2.82 Angstroms, c' est à dire dans la bande amorphe si tuée dans le diagramme du ( K)-PS du Tableau A, entre 2.79 et 3.23 Angstroms.The X-ray examination made as in example 2), shows the same lines of (K) -PS with in addition weakly intense lines at 3.24 / 2.95 / 2.88 / 2.82 Angstroms, ie in the band amorphous if killed in the diagram of (K) -PS in Table A, between 2.79 and 3.23 Angstroms.
Le rapport H2O/A12O3 peut varier entre 10 et 25. On préférera cependant se rapprocher des valeurs comprises entre 14 et 20. Des valeurs plus grandes augmentent la porosité du produit obtenu , alors que des valeurs plus basses semblent perturber la phase silicate de potassium de la solution solide du composé polymérique, accompagnées de migration et d' une alcalinité libre. Aussi, dans la pratique, préfère-t-on utiliser des mélanges réactionnels dont les rapports molaires des oxydes réactifs correspondent au Tableau E;The H 2 O / A1 2 O 3 ratio can vary between 10 and 25. However, it is preferable to approach values between 14 and 20. Larger values increase the porosity of the product obtained, while lower values seem to disturb the potassium silicate phase of the solid solution of the polymeric compound, accompanied by migration and free alkalinity. Also, in practice, we prefer to use reaction mixtures whose molar ratios of reactive oxides correspond to Table E;
Exemple 4 ) Example 4)
On prépare 860 grammes du mélange réactionnel de l ' Exemple 1 ) et on y ajoute 220 grammes de Muscovite de granulométrie inférieure à 120 microns et 90 grammes de Fluorure de Calcium F2Ca en poudre fine . La résine visqueuse ainsi obtenue sert à agglomérer 1kg 150 grammes de sable de Zircon. Ce mélange est coulé par vibration dans un moule qui est ensuite placé à 85°C pendant lh30 min. Après sèche, le pro duit obtenu a une densité de 3,0 grammes par millilitre. Son aspect est brillant , sa dureté est de 6 dans l 'échelle de Mohs . L ' analyse du diagramme des Rayons X est très délicate , car outre les raies intenses du Zircon et du Fluorure de Calcium , celles très nombreuses de la Muscovite recouvrent pratiquement toutes les raies caractéristiques du ( K)-PS. Exemple 5 )860 grams of the reaction mixture of Example 1) are prepared and 220 grams of Muscovite with a particle size of less than 120 microns and 90 grams of Calcium Fluoride F 2 Ca in fine powder are added thereto. The viscous resin thus obtained is used to agglomerate 1 kg 150 grams of Zircon sand. This mixture is poured by vibration into a mold which is then placed at 85 ° C for 1 h 30 min. After drying, the product obtained has a density of 3.0 grams per milliliter. Its appearance is brilliant, its hardness is 6 in the Mohs scale. The analysis of the X-ray diagram is very delicate, because in addition to the intense lines of Zircon and Calcium Fluoride, those very numerous of Muscovite cover practically all the lines characteristic of (K) -PS. Example 5)
On prépare un mélange réactionnel selon l ' Exemple 1 ) . Après maturation on applique au pinceau, la résine ainsi formée , en très fine couche sur une empreinte constituant le négatif d ' une sculpture . P arallèlement, on introduit dans un mélangeur 5 kilogrammes de silex de granulométrie comprise entre 0 ,5 et 5 mm , et on y ajoute 0, 5 kilogrammes soit 10% en poids du silex, de cette même résine minérale . Le mé lange est vibré dans l ' empreinte déjà enduite et on recouvre avec un film de polyéthylène et on laisse durcir à la température ambiante (25° ) . On démoule , le lendemain , une sculpture possèdant une peau extrèmement fine, dure et brillante. Les mélanges réactionnels silicoaluminates de potassium décrits dans cete invention permettent de fabriquer des objets moulés résultant de l ' agglomération de 5 à 95 parties en poids de produits et charges minérales et/ou organiques, avec 5 à 95 parties en poids d' un liant constitué d'un commposé polymérique minéral dont la composition exprimée en terme d'oxyde est yK2O:Al2O3 :xSiO2:wH2O dans la forme hydratée de laquelle "w" est au plus égal à 4, "x" est une valeur comprise entre 3 ,3 et 4,5 environ, "y" est une valeur comprise entre 0,9 et 1,6 environ . Le composé polymérique minéral est une solution solide comprenant 35 à 90 parties en poids d'un polysilicate de potassium de formuleA reaction mixture is prepared according to Example 1). After maturation, the resin thus formed is applied with a brush, in a very thin layer on an imprint constituting the negative of a sculpture. At the same time, 5 kilograms of flint with a particle size between 0.5 and 5 mm are introduced into a mixer, and 0.5 kilograms, or 10% by weight of the flint, of this same mineral resin, are added thereto. To me the cloth is vibrated in the already coated impression and covered with a polyethylene film and allowed to harden at room temperature (25 °). The next day we unmold a sculpture with extremely thin, hard and shiny skin. The potassium silicoaluminate reaction mixtures described in this invention make it possible to manufacture molded articles resulting from the agglomeration of 5 to 95 parts by weight of mineral and / or organic products and fillers, with 5 to 95 parts by weight of a binder consisting of a mineral polymeric compound whose composition expressed in terms of oxide is yK 2 O: Al 2 O 3 : xSiO 2 : wH 2 O in the hydrated form of which "w" is at most equal to 4, "x" is a value between approximately 3, 3 and 4.5, "y" is a value between approximately 0.9 and 1.6. The inorganic polymeric compound is a solid solution comprising 35 to 90 parts by weight of a potassium polysilicate of formula
(y 1) K2O : (x-2)SiO2 (w-1) H2O pour 10 à 65 parties en poids de polysialate de potassium de formule(y 1) K 2 O: (x-2) SiO 2 (w-1) H 2 O for 10 to 65 parts by weight of potassium polysialate of formula
(K)n (-Si-O-Al-O-) n, nH2O O O et dont le diagramme de diffraction aux Rayons X est voisin du minéral naturel Kaliophilite selon le Tableau A.(K) n (-Si-O-Al-O-) n , nH 2 OOO and whose X-ray diffraction diagram is close to the natural mineral Kaliophilite according to Table A.
Selon les charges utilisées , comme par exemple la Muscovite, les aluminosilicates naturels ou synthétiques , le Zircon , le Carbure de Silicium les chamottes , ou autres produits céramiques ou réfractaires , les objets moulés possèdent une très grande résistance au choc thermique. Bien que l 'on puisse appliquer directement la flamme d' un chalumeau sur les objets destinés à subir des températures élevées , comprises entre 300ºC et 1200°C, il est préférable de faire subir un traitement thermique à une température au moins égale à 325°C, afin d ' éliminer l ' eau de constitution. Le composé polymérique minéral est déshydraté et déshydroxylé et est transformé en un produit de qualité équivalente ou supérieure à celle des matériaux céramiques , et possède une excellente stabilité thermique. Sa composition exprimée sous forme des oxydes est alors : yK2O:Al2O3 :xSiO2 dans laquelle "x" est une valeur comprise entre 3,3 et 4, 5 environ ,Depending on the fillers used, such as Muscovite, natural or synthetic aluminosilicates, Zircon, Silicon Carbide, chamottes, or other ceramic or refractory products, the molded objects have very high resistance to thermal shock. Although the flame of a blowtorch can be applied directly to objects intended to undergo high temperatures, between 300ºC and 1200 ° C, it is preferable to subject it to a heat treatment at a temperature at least equal to 325 ° C, in order to remove the constitution water. The inorganic polymeric compound is dehydrated and dehydroxylated and is transformed into a product of equivalent or higher quality than that of ceramic materials, and has excellent thermal stability. Its composition expressed in the form of oxides is then: yK 2 O: Al 2 O 3 : xSiO 2 in which "x" is a value between 3.3 and 4.5 approximately,
"y" est une valeur comprise entre 0, 9 et 1 , 6 environ. Il est constitué d'une solution solide comprenant une phase de polysilicate de potassium de composition"y" is a value between 0.9 and 1.6, approximately. It consists of a solid solution comprising a potassium polysilicate phase of composition
(y-1)K2O:(x-2)SiO2 et une phase de Polysialate (K)PS de formule (K)n (-Si-O-Al-O-)n (y-1) K 2 O: (x-2) SiO 2 and a phase of Polysialate (K) PS of formula (K) n (-Si-O-Al-O-) n
O O Les mélanges réactionnels silicoaluminates de potassium décrits dans cette invention constituent une résine minérale pouvant être utilisée avec au moins une charge minérale et/ ou organique, ou en tant que liant ou ciment. La polycondensation ou le durcissement se fait soit à la température ambiante, soit jusqu'à une température inférieure à 120ºC. Toutes charges, ainsi que des produits auxilliaires compatibles peuvent être ajoutés, nous citerons sans limitation d'aucune sorte: les colorants et pigments , les agents de debullage, les fibres de renforce ment, les agents hydrofugeants.O O The potassium silicoaluminate reaction mixtures described in this invention constitute a mineral resin which can be used with at least one mineral and / or organic filler, or as a binder or cement. Polycondensation or hardening takes place either at room temperature or up to a temperature below 120ºC. All fillers, as well as compatible auxiliary products can be added, we will cite without limitation of any kind: dyes and pigments, debubbling agents, reinforcing fibers, water-repellent agents.
Les objets moulés réalisés à l'aide de l'invention ont des utilisations multiples selon la caractéristique physique, mécanique ou chimique mise en jeu: dans l'industrie, le bâtiment, la décoration, sous forme d'objet, de moule, d'outil, de bloc, de panneau, de revètement. Ils peuvent subir multiples traitements physico-chimiques, physiques ou mécaniques postérieurs, ainsi que des opérations d'apprêt ou de finition, de bouchage de la porosité. Si nécessaire, ils subiront uri traitement thermique à une température au moins égale à 325°C environ, les transformant en produits ayant des qualités céramiques, en parti- culier une excellente stabilité thermique et dimensionnelle.The molded objects produced using the invention have multiple uses depending on the physical, mechanical or chemical characteristic involved: in industry, construction, decoration, in the form of an object, a mold, tool, block, panel, coating. They can undergo multiple subsequent physico-chemical, physical or mechanical treatments, as well as priming or finishing operations, plugging the porosity. If necessary, they will undergo a heat treatment at a temperature at least equal to approximately 325 ° C., transforming them into products having ceramic qualities, in particular excellent thermal and dimensional stability.
Bien entendu, diverses modifications peuvent être apportées par l'homme de métier aux polymères et procédés qui viennent d'être décrits uniquement à titre d'exemple , comme par exemple en changeant la nature et/ou la granulométrie des charges minérales, sans sortir du cadre de l'invention. Of course, various modifications can be made by those skilled in the art to the polymers and processes which have just been described by way of example only, such as by changing the nature and / or the particle size of the mineral fillers, without departing from the scope of the invention. part of the invention.

Claims

REVENDICATIONS
1.) Composé polymérique minéral de la famille des silicoaluminates, dont la composition exprimée en terme d'oxyde est: y K2O : Al2O3 : xSiO2 : wH2O dans la forme hydratée de laquelle "w" est une valeur au plus égale à 4,"x" est une valeur comprise entre 3,3 et 4,5 environ, "y" est une valeur comprise entre 0,9 et 1,6 environ, caractérisé en ce que ce composé polymérique minéral est constitué d'une solution solide comprenant une phase de polysilicate de potassium de composition (y-1)K2O:(x-2)SiO2:(w-1)H2O et une phase de polymère Polysialate de potassium de formule1.) Mineral polymeric compound of the family of silicoaluminates, the composition of which, expressed in terms of oxide, is: y K 2 O: Al 2 O 3 : xSiO 2 : wH 2 O in the hydrated form of which "w" is a value at most equal to 4, "x" is a value between approximately 3.3 and 4.5, "y" is a value between approximately 0.9 and 1.6, characterized in that this inorganic polymeric compound is consisting of a solid solution comprising a potassium polysilicate phase of composition (y-1) K 2 O: (x-2) SiO 2 : (w-1) H 2 O and a potassium polysialate polymer phase of formula
(K)n(-Si-O-Al-O-)n,nH2O(K) n (-Si-O-Al-O-) n , nH 2 O
O O le dit polymère Polysialate de potassium ayant un diagramme aux Rayons X voisin de celui d'un minéral naturel connu sous le nom de Kaliophilite KAlSiO4.OO the so-called potassium Polysialate polymer having an X-ray diagram close to that of a natural mineral known as Kaliophilite KAlSiO 4 .
2. ) Composé polymérique selon 1), caractérisé en ce que la solution solide commprend 35 à 90 parties en poids du polysilicate de potassium pour 10 à 65 parties en poids de Polysialate de potassium de formule (K)n(-Si-O-Al-O-)n,nH2O2.) Polymeric compound according to 1), characterized in that the solid solution comprises 35 to 90 parts by weight of potassium polysilicate per 10 to 65 parts by weight of potassium polysialate of formula (K) n (-Si-O- Al-O-) n , nH 2 O
O OO O
3. ) Procédé de préparation d'un composé polymérique selon 2), caractérisé en ce qu'il consiste à préparer un mélange réactionnel à base de silicate de potassium, de potasse KOH et d'oxyde aluminosilicate ( Si2O5 , A12O2 )n , tel que les rapports molaires des produits réactionnels exprimés en terme d'oxyde soient compris ou égaux aux valeurs suivantes:3.) Process for preparing a polymeric compound according to 2), characterized in that it consists in preparing a reaction mixture based on potassium silicate, potassium KOH and aluminosilicate oxide (Si 2 O 5 , A1 2 O 2 ) n , such that the molar ratios of the reaction products expressed in terms of oxide are included or equal to the following values:
K2O/Al2O3 0,23 à 0,48K 2 O / Al 2 O 3 0.23 to 0.48
SiO2/Al2O3 3,3 à 4,5 H2O/Al2O3 10 à 25SiO 2 / Al 2 O 3 3.3 to 4.5 H 2 O / Al 2 O 3 10 to 25
K2O/Al2O3 0,9 à 1,60 puis à faire durcir le dit mélange réactionnel à une température inférieure à 120°C.K 2 O / Al 2 O 3 0.9 to 1.60 and then to harden said reaction mixture at a temperature below 120 ° C.
4.) Procédé de préparation d'un composé polymérique selon 3) caractéri-se en ce que on ajoute au dit mélange réactionnel au moins une charge minérale, et on effectue le durcissement dans un moule.4.) Process for the preparation of a polymeric compound according to 3) characterized in that at least one mineral filler is added to the said reaction mixture, and the curing is carried out in a mold.
5.) Procédé de préparation d'un objet moulé à l'aide d'un composé polymérique contenant en solution solide une phase de polysilicate de potassium et une phase de Polysialate de potassium de formule (K)n (-Si-O-Al-O-)n,nH2O5.) Process for the preparation of a molded object using a polymeric compound containing in solid solution a phase of potassium polysilicate and a phase of potassium polysialate of formula (K) n (-Si-O-Al-O-) n , nH 2 O
O O caractérisé en ce qu'il consiste à préparer un mélange de silicate de potassium, de. potasse KOH et d'oxyde aluminosilicate (Si2O5,Al2O2)n OO characterized in that it consists in preparing a mixture of potassium silicate, of. potassium KOH and aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n
tel que les rapports molaires des produits, réactionnels exprimés en terme d'oxyde correspondent à environsuch that the molar ratios of the products, reaction expressed in terms of oxide correspond to approximately
K2O/SiO2 0,30 à 0,38 SiO2/Al203 4,0 à 4,2 H2O/Al2O3 14 à 20 K2O/A12O3 1,3 à 1,52 puis à mélanger avec au moins une charge minérale et/ou organique, et à effectuer le durcissement dans un moule. K 2 O / SiO 2 0.30 to 0.38 SiO 2 / Al 2 0 3 4.0 to 4.2 H 2 O / Al 2 O 3 14 to 20 K 2 O / A1 2 O 3 1.3 to 1.52 then to mix with at least one mineral and / or organic filler, and to perform the hardening in a mold.
6.) Objet moulé, résultant de l'agglomération de 5 à 95 parties en poids de produits et charges minérales et/ou organiques avec 5 à 95 parties en poids d'un liant constitué d'un composé polymérique minéral selon l'une quelconque des revendications 1) ou 2).6.) Molded object, resulting from the agglomeration of 5 to 95 parts by weight of mineral and / or organic products and fillers with 5 to 95 parts by weight of a binder consisting of a mineral polymeric compound according to any one of claims 1) or 2).
7. ) Procédé de préparation d'objets moulés ayant des propriétés céramiques, caractérisé en ce que le composé polymérique minéral qui contient une solution solide comprenant une phase de polysilicate de potassium et une phase de Polysialate de Potassium de formule7.) Process for preparing molded objects having ceramic properties, characterized in that the inorganic polymeric compound which contains a solid solution comprising a potassium polysilicate phase and a potassium polysialate phase of formula
(K)n (-Si-O-Al-O-)n,nH2O(K) n (-Si-O-Al-O-) n , nH 2 O
O O est déshydraté et déshydroxylé à une température au moins égale à 325 "C.O O is dehydrated and dehydroxylated at a temperature at least equal to 325 "C.
8. ) Objet céramique moulé contenant un composé polymérique minéral dont la composition exprimée en terme des oxydes est yK2O:Al2O3:xSiO2 dans laquelle "x" est une valeur comprise entre 3,3 et 4,5 environ, "y" est une valeur comprise entre 0,9 et 1,6 environ, le dit composé polymérique est constitué d'une solution solide comprenant une phase de polysilicate de potassium de composition8.) molded ceramic object containing a mineral polymeric compound whose composition expressed in terms of oxides is yK 2 O: Al 2 O 3 : xSiO 2 in which "x" is a value between 3.3 and 4.5 approximately, "y" is a value between 0.9 and 1.6 approximately, the said polymeric compound consists of a solid solution comprising a potassium polysilicate phase of composition
(y-1)K2O:(x-2)SiO2 et une phase de Polysialate de potassium de formule(y-1) K 2 O: (x-2) SiO 2 and a potassium polysialate phase of formula
(K)n(-Si-O-Al-O-)n O O REVENDICATIONS MODIFIEES(K) n (-Si-O-Al-O-) n OO AMENDED CLAIMS
(reçues par le Bureau international le 10 fevrier 1982 (10.02.82))(received by the International Bureau on February 10, 1982 (10.02.82))
1. ) Composé polymérique minéral de la famille des silicoaluminates , dont la composition exprimée en terme d' oxyde est : yK2O : Al2O3 :xSiO2 : wH2O dans la forme hydratée de laquelle "w" est une valeur au plus égale à 4, "x" est une valeur comprise entre 3,3 et 4,5 environ , "y" est une valeur comprise entre 0,9 et 1 ,6 environ, caractérisé en ce que ce composé polymérique minéral est constitué d ' une solution solide comprenant une phase de polysilicate de potassium de composition (y-1)K2O: (x-2)SiO2 : (w-1 )H2O et une phase de polymère Polysialate de potassium de formule le dit polymère Polysialate de potassium ayant un diagramme aux Rayons X voisin de celui d ' un minéral naturel connu sous le nom de Kaliophilite KAlSiO4.1.) Mineral polymeric compound of the family of silicoaluminates, the composition of which expressed in terms of oxide is: yK 2 O: Al 2 O 3 : xSiO 2 : wH 2 O in the hydrated form of which "w" is a value at most equal to 4, "x" is a value between approximately 3.3 and 4.5, "y" is a value between approximately 0.9 and 1.6, characterized in that this inorganic polymeric compound consists of a solid solution comprising a potassium polysilicate phase of composition (y-1) K 2 O: (x-2) SiO 2 : (w-1) H 2 O and a potassium polysialate polymer phase of formula the said potassium polysialate polymer having an X-ray diagram close to that of a natural mineral known under the name of Kaliophilite KAlSiO 4 .
2. ) Composé polymérique selon 1) , caractérisé en ce que la solution solide comprend 35 à 90 parties en poids du polysilicate de potassium pour 10 à 65 parties en poids de Polysialate de potassium de formule 2.) Polymeric compound according to 1), characterized in that the solid solution comprises 35 to 90 parts by weight of potassium polysilicate per 10 to 65 parts by weight of potassium polysialate of formula
3. ) ( modifiée) . Procédé de préparation d ' un composé polymérique selon 2) , caractérisé en ce qu ' il consiste à préparer un mélange réactionnel à base de silicate de potassium, de potasse KOH et d' oxyde aluminosilicate(Si2O5,Al2O2) n dont le cation Al est en position tétracoor donnée, tel que les rapports molaires des produits réactionnels exprimés en terme d 'oxyde soient compris ou égaux aux valeurs suivantes :3.) (modified). Process for the preparation of a polymeric compound according to 2), characterized in that it consists in preparing a reaction mixture based on potassium silicate, potassium KOH and aluminosilicate oxide (Si 2 O 5 , Al 2 O 2 ) n whose cation Al is in the given tetracoor position, such that the molar ratios of the reaction products expressed in terms of oxide are included or equal to the following values:
K2O/SiO2 0,23 à 0,48 SiO2/Al2O3 3,3 à 4,5 H2O/A12O3 10 à 25K 2 O / SiO 2 0.23 to 0.48 SiO 2 / Al 2 O 3 3.3 to 4.5 H 2 O / A1 2 O 3 10 to 25
K2O/A12O3 0 ,9 à 1 , 60 puis à faire durcir le dit mélange réactionnel à une température inférieure à 120°C.K 2 O / A1 2 O 3 0, 9 to 1, 60 then hardening said reaction mixture at a temperature below 120 ° C.
4. ) (modifiée ) . Procédé de préparation d ' un composé polymérique selon 3) , caractérisé en ce que avant de faire durcir ce dit mélange réactionnel, on ajoute au dit mélange réactionnel une quantité substantielle d ' au moins une charge minérale, pour former le dit composé polymérique.4.) (modified). Process for the preparation of a polymeric compound according to 3), characterized in that before hardening said reaction mixture, a substantial amount of at least one mineral filler is added to said reaction mixture to form said polymeric compound.
5. ) (modifiée) . Procédé de préparation d 'un objet moulé consistant à pré parer un mélange aqueux silico-aluminate de potassium, à base de silicate de potassium, de potasse KOH et d'oxyde aluminosilicate5.) (modified). Method for preparing a molded object consisting of pre to coat an aqueous mixture of potassium silico-aluminate, based on potassium silicate, potassium KOH and aluminosilicate oxide
(Si2O5,Al2O2)n dont le cation Al est en position tétracoordonnee, tel que les rapports molaires des produits réactionnels exprimés en terme d'oxyde soient compris ou égaux aux valeurs suivantes:(Si 2 O 5 , Al 2 O 2 ) n in which the cation Al is in the tetracoordinated position, such that the molar ratios of the reaction products expressed in terms of oxide are included or equal to the following values:
K2O/SiO2 0,30 à 0,38 SiO2/Al2O3 4,0 à 4,2 H2O/A12O3 14 à 20 K2O/A12O3 1,3 à 1,52 puis à ajouter dans le dit mélange silico-aluminate une quantité substantielle d'au moins une charge minérale et/ou organique, puis à mettre le dit mélange silico-aluminate/charge dans un moule, puis à faire durcir le dit mélange silico-aluminCe/charge dans le dit moule pour obtenir un objet moulé solide résultant de la formation d'un composé poly mérique qui contient en solution solide une phase de polysilicate de potassium et une phase de polymère poly(sialate) de potassium de formule: le dit polymère Poly(sialate) de potassium ayant un diagramme aux rayons X voisin de celui d'un minéral naturel connu sous le nom de Kaliophilite KAlSiO4.K 2 O / SiO 2 0.30 to 0.38 SiO 2 / Al 2 O 3 4.0 to 4.2 H 2 O / A1 2 O 3 14 to 20 K 2 O / A1 2 O 3 1.3 to 1.52 then add to the said silico-aluminate mixture a substantial amount of at least one mineral and / or organic filler, then put the said silico-aluminate / filler mixture in a mold, then harden the said mixture silico-aluminCe / filler in said mold to obtain a solid molded object resulting from the formation of a polymeric compound which contains in solid solution a phase of potassium polysilicate and a phase of potassium poly (sialate) polymer of formula: the said potassium poly (sialate) polymer having an X-ray diagram close to that of a natural mineral known as Kaliophilite KAlSiO 4 .
6. ) (supprimée)6.) (deleted)
7. ) (supprimée). 8. ) (modifiée). Procédé de préparation selon la revendication 5) caractérisé en ce que le dit composé polymérique minéral a une composition exprimée en terme des oxydes : yK2O:Al2O3:xSiO2 dans laquelle "x" est une valeur comprise entre 3,3 et 4,5 environ, "y" est une valeur comprise entre 0,9 et 1,6 environ, le dit composé polymérique est constitué d'une solution solide comprenant une phase de polysilicate de potassium de composition7.) (deleted). 8.) (modified). Preparation process according to claim 5) characterized in that said inorganic polymeric compound has a composition expressed in terms of oxides: yK 2 O: Al 2 O 3 : xSiO 2 in which "x" is a value between 3.3 and approximately 4.5, “y” is a value between approximately 0.9 and 1.6, said polymeric compound consists of a solid solution comprising a potassium polysilicate phase of composition
(y-1)K2O:(x-2)SiO2 et une phase de Poly(sialate) de potassium de formule (y-1) K 2 O: (x-2) SiO 2 and a potassium poly (sialate) phase of formula
EP81902468A 1980-09-03 1981-09-02 Synthetic mineral polymer compound of the silicoaluminates family and preparation process; molded articles containing such polymer compound and production process thereof Expired EP0066571B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT81902468T ATE14107T1 (en) 1980-09-03 1981-09-02 POLYMERIC INORGANIC SILICOALUMINATE, ITS PRODUCTION AND USES.

Applications Claiming Priority (2)

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FR8018971 1980-09-03
FR8018971A FR2489291A1 (en) 1980-09-03 1980-09-03 MINERAL POLYMERIC COMPOUND AND PROCESS FOR OBTAINING THE SAME

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EP0066571B1 EP0066571B1 (en) 1985-07-03

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EP (1) EP0066571B1 (en)
FR (1) FR2489291A1 (en)
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US4472199A (en) 1984-09-18
SU1347864A3 (en) 1987-10-23
FR2489291A1 (en) 1982-03-05
FR2489291B3 (en) 1983-05-20
EP0066571B1 (en) 1985-07-03
WO1982000816A1 (en) 1982-03-18

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